Winch drum tension isolation system

ABSTRACT

A winch drum tension isolation system includes a winch drum including an outwardly extending flange, the flange including a plurality of holes spaced along the flange. The winch drum tension isolation system also includes a locking mechanism positioned proximate the winch drum and including a locking member engageable with the flange. The locking member is movable between a first position, in which the locking member is received in one of the plurality of holes to prevent rotation of the winch drum, and a second position, in which the locking member is spaced apart from the flange to permit rotation of the winch drum.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.61/778,824, filed Mar. 13, 2013, the entire contents of which areincorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to a conveyor system for an undergroundmining machine, and in particular an isolation system.

BACKGROUND OF THE INVENTION

Large, heavy winches are used in the underground mining industry. Theseheavy winches are used to keep tension on the conveyors (e.g., belts),which carry material out of the underground mine. The winches include awinch drum (i.e., a rotating piece upon which a winch rope is wound), anelectric motor and gearbox for turning the winch drum, and a park brake.Occasionally a conveyor experiences an emergency stop and the park brakesees dynamic braking loads causing it to overheat and seize. The seizedpark brake ends up trapping stored energy in the conveyor, and the loadcannot be released from the seized brake. This situation placesoperators at risk when attempting to repair or replace the motor andgearbox or park brake.

SUMMARY

In accordance with one construction, a winch drum tension isolationsystem includes a winch drum including an outwardly extending flange,the flange including a plurality of holes spaced along the flange. Thewinch drum tension isolation system also includes a locking mechanismpositioned proximate the winch drum and including a locking memberengageable with the flange. The locking member is movable between afirst position, in which the locking member is received in one of theplurality of holes to prevent rotation of the winch drum, and a secondposition, in which the locking member is spaced apart from the flange topermit rotation of the winch drum.

In accordance with another construction, a conveyor system includes awinch frame, a conveyor extending through the winch frame, and a winchdrum coupled to the winch frame that drives the conveyor, the winch drumincluding an outwardly extending flange. The flange includes a pluralityof holes spaced along the flange. The conveyor system also includes atorque arm coupled to both the winch frame and the winch drum. Theconveyor system also includes a motor and gearbox that drives rotationof the winch drum, and a park brake that provides emergency brakingforce to the motor and gear box. The conveyor system also includes alocking mechanism positioned proximate the winch drum and including alocking member engageable with the flange, the locking member movablebetween a first position, in which the locking member is received in oneof the plurality of holes to prevent rotation of the winch drum, and asecond position, in which the locking member is spaced apart from theflange to permit rotation of the winch drum.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of a conveyor system.

FIG. 2 is a top perspective view of the conveyor system of FIG. 1,illustrating a gearbox torque arm.

FIGS. 3 and 4 are top perspective views of a winch drum tensionisolation system for the conveyor system of FIG. 1.

FIG. 5 is a top plan view of the winch drum tension isolation system ofFIGS. 3 and 4.

FIG. 6 is a top perspective view of the conveyor system of FIG. 1,illustrating a ram for actuating the gearbox torque arm.

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limited.

DETAILED DESCRIPTION

FIGS. 1 and 2 illustrate a conveyor system 10 that is used in anunderground mining environment to move material out of, or within, theunderground mine. The conveyor system 10 includes a winch drum 14, amotor 17 and gearbox 18 that drive rotation of the winch drum 14, and apark brake 22 that provides emergency braking force to the motor 17 andgearbox 18. The conveyor system 10 also includes a winch frame 26, and aconveyor 30 that extends through the winch frame 26. The winch drum 14is coupled to the winch frame 26. A winch rope (not shown) is woundabout the winch drum 14, and is used to move the conveyor 30. The winchdrum 14 is a large-scale structure capable of constant application atapproximately 80 kN (18000 lbf) and crash loading of approximately 297kN (67500 lbf). Crash loading refers to stopping tensions caused by afully loaded conveyor 30 not properly starting (e.g., an “aborted start”or a tripped condition during fully loaded running or an emergency stopcondition during fully loaded running).

The conveyor system 10 also includes a torque arm 34. The torque arm 34is coupled to both the winch drum 14 and to the winch frame 26, andabsorbs torsional stress developed by rotation of the winch drum 14relative to the frame 26.

With reference to FIGS. 1-6, the winch drum 14 includes a pair ofoutwardly extending flanges 38, 40 located at opposite ends of the drum14. In the illustrated construction, the flange 38 located opposite thearm 34 includes holes 42. The flange 38 extends circumferentially abouta rotational axis 44 of the drum 14, and the holes 42 are positionedcircumferentially about the flange 38. The holes 42 are spaced evenlyapart from each other along the flange 38. As illustrated in FIG. 2, theflange 38 is a separate member coupled to a central portion 46 of thewinch drum 14. In other constructions, the flange 38 is integrallyformed with the central portion 46 or the flange 38 is retrofitted to anexisting winch drum 14.

The flange 38 has a diameter greater than a diameter of the centralportion 46 of the winch drum 14, and the holes 42 are located generallynear an outer edge 50 of the flange 38, such that the holes 42 arelocated radially exterior to the central portion 46.

With reference to FIGS. 3-5, the conveyor system 10 includes a lockingmechanism 52 positioned proximate the winch drum 14. The lockingmechanism 52, in conjunction with the flange 38, forms part of anoverall winch drum tension isolation system that isolates tensionbuild-up in the conveyor 30 in the event of a park brake 22 seizure.

The locking mechanism 52 of the winch drum tension isolation systemincludes a locking member 54 located within a housing 58. In theillustrated construction, the locking member 54 is a spring-loaded pindisposed in the housing 58, though in other constructions the lockingmember 54 is another structure, including a hydraulically activated pin,etc. The housing 58 is coupled to the winch frame 26, and the lockingmember 54 slides within the housing 58. The locking member 54 includes adistal end 62 positioned proximate the flange 38 of the drum 14, and thedistal end 62 is received in one of the holes 42 of the flange 38depending upon a position of the locking member 54. When the lockingmember 54 is in a first position, the distal end 62 of the lockingmember 54 is received in one of the holes 42 and the locking member 54inhibits movement of the drum 14. When the locking member 54 is in asecond position, the distal end 62 is spaced apart from and does notengage the flange 38 such that movement of the drum 14 is permitted.

The locking mechanism 52 includes a restraining mechanism 66 thatrestrains movement of the locking member 54 relative to the winch drum14. In the illustrated construction, the restraining mechanism 66includes a flange 67 on the winch frame 26 and a flange 68 on an end ofthe locking member 54. As illustrated in FIGS. 3 and 4, the flanges 67and 68 include holes 69. When the restraining mechanism 66 is in alocked position, the holes 69 are aligned, and a bolt (not shown) ispassed through the flanges, thereby locking movement of the lockingmember 54. To release the restraining mechanism 66, the bolt is removed,and the flange 68 is rotated relative to the flange 67 (e.g., 90degrees) so that the flange 68 is able to move toward the flange 38.Once released, the locking member 54 (i.e., the spring-loaded pin in theillustrated construction) moves toward the flange 38, and the distal end62 of the locking member 54 moves toward one of the holes 42. In theillustrated construction, a spring element (not shown) is located insidethe housing 58 and biases the locking member 54 toward the flange 38.When the restraining mechanism 66 is in a locked position, the springelement maintains potential energy in the spring that is released andcauses movement of the locking member 54 toward the flange 38 once therestraining mechanism 66 is unlocked and the flange 68 is rotated. Inother constructions, different restraining mechanisms are used,including restraining mechanisms that lock the locking member 54 at morethan one position, restraining mechanisms that utilize padlocks to lockthe locking member 54, etc.

The locking mechanism 52 is positioned on the winch frame 26 such thatthe locking member 54, and in particular the distal end 62, is generallyaligned radially with the holes 42. Based on rotational positioning ofthe winch drum 14, the distal end 62 extends through one of the holes 42when the restraining member 66 is released.

With reference to FIGS. 3-5, the locking mechanism 52 includes guidemembers 70 located on either side of the flange 38. Each of the guidemembers 70 includes an opening 74 for receiving the locking member 54and guiding the locking member 54 into alignment with one of the holes42.

In the illustrated construction, the flange 38 and the locking member 54prevent rotation of the winch drum 14 in the case of a brake seizure inthe park brake 22, and isolate tension that builds up in the conveyor30. As noted above, occasionally the conveyor 30 experiences anemergency stop and the park brake 22 sees dynamic braking loads causingthe park brake 22 to overheat and seize. The seized park brake 22 endsup trapping stored energy in an elastic belt of the conveyor 30, and theload cannot be released from the seized park brake 22. This situationplaces operators at risk to replace or repair the motor 17, gearbox 18or park brake 22, since the winch drum 14 could, if not restrained,suddenly and without warning begin rotating again, thereby releasing thestored energy and causing injury or damage to a nearby operator or theconveyor system 10.

In order to remove the stored energy safely, the flange 38 and thelocking member 54 are utilized to lock rotation of the winch drum 14 andisolate the tension in the conveyor 30 while replacement and/or repairsare made. In particular, if the distal end 62 of the locking member 54is aligned with one of the holes 42 after seizure, the restrainingmechanism 66 is released (as described above), and the distal end 62 ofthe locking member 54 moves towards the hole 42. In the illustratedconstruction, the locking member 54 is a biasing member biased towardthe holes 42 by a spring element (not shown). Thus, when the restrainingmember 66 is released, the locking member automatically moves toward thealigned hole 42.

With the locking member 54 received by the aligned hole 42 and the guidemembers 70, rotation of the winch drum 14 is prevented. With rotation ofthe winch drum 14 prevented, the motor 17, gear box 18, park brake 22,and/or other structure are removed and/or repaired, and the storedenergy is removed safely without the risk of the winch drum 42 causinginjury or damage.

If the distal end 62 of the locking member 54 is not aligned with one ofthe holes 42 after seizure, then the torque arm 34 is used to rotate thewinch drum 14 until one of the holes 42 aligns with the distal end 62 ofthe locking member 54. For example, and with reference to FIG. 6, thetorque arm 34 is raised or lowered via a ram 74, though in otherconstructions other mechanisms are used. The ram 74 is connected to anexternal hydraulic system, hand pump, or other source of pressure (notshown). Additionally, the torque arm 34 is coupled to an anchor point78, which is coupled to the winch frame 26 by an anchor pin 82. In orderto initially release the anchor pin 82 (which is under a load), the ram74 is activated to move the torque arm 34 slightly, relieving the stresson the anchor pin 82, such that the anchor pin 82 is removed, and thetorque arm 34 is then rotated until one of the holes 42 is aligned withthe distal end 62 of the locking member 54.

The motor 17 and gearbox 18 are advantageously not needed to rotate thewinch drum 14 such that one of the holes 42 in the flange 38 aligns withthe locking member 54. Rather, the torque arm 34 is raised or loweredsolely with the ram 74 so as to rotate the winch drum 14 in eitherdirection about the rotational axis 44, until one of the holes 42 isaligned with the locking member 54. With the hole 42 aligned, therestraining mechanism 66 is then unlocked, for example by removing abolt from holes 69 and rotating the flange 67 relative to the flange 68,and the distal end 62 of the locking member 54 is biased (in theillustrated construction automatically via the biasing force of thespring element) toward the flange 38 until the distal end 62 is seatedin the aligned hole 42 and the guide members 70, thereby lockingrotation of the winch drum 14.

Once the motor 17, gear box 18, park brake 22, and/or other structure isrepaired and/or replaced, the locking member 54 is removed from the hole42 (e.g., by a user or machine pulling the locking member 54 from thehole 42 while gripping the flange 68). The torque arm 34 is moved againwith the ram 74, and the anchor pin 82 is inserted back in the anchorpoint 78. With the locking member 54 removed, the restraining mechanism66 is applied to the locking member 54 to prevent the locking member 54from re-engaging the flange 38. In the illustrated construction, theflange 68 is rotated relative to the flange 67 until the holes 69 align,and the bolt is placed back in the holes 69.

Although the invention has been described in detail with reference tocertain preferred embodiments, variations and modifications exist withinthe scope and spirit of one or more independent aspects of the inventionas described.

The invention claimed is:
 1. A winch drum tension isolation systemcomprising: a winch drum including an outwardly extending flange, theflange including a plurality of holes spaced along the flange; a lockingmechanism positioned proximate the winch drum and including a lockingmember engageable with the flange, the locking member movable between afirst position, in which the locking member is received in one of theplurality of holes to prevent rotation of the winch drum, and a secondposition, in which the locking member is spaced apart from the flange topermit rotation of the winch drum; and a motor and gearbox coupled tothe winch drum.
 2. The winch drum tension isolation system of claim 1,wherein the winch drum includes a central portion having a firstdiameter, and the flange has a second diameter greater than the firstdiameter.
 3. The winch drum tension isolation system of claim 1, whereinthe flange includes an outer radial circumference.
 4. The winch drumtension isolation system of claim 1, wherein the plurality of holes arespaced circumferentially about the flange.
 5. The winch drum tensionisolation system of claim 1, wherein the plurality of holes are spacedevenly apart along the flange.
 6. The winch drum tension isolationsystem of claim 1, wherein the locking member is a spring-loaded pin. 7.The conveyor system of claim 6, wherein the spring-loaded pin includes aspring that biases a pin into one of the plurality of holes.
 8. Thewinch drum tension isolation system of claim 1, wherein the lockingmechanism includes a housing and the locking member is slidable throughthe housing.
 9. The conveyor system of claim 8, wherein the housing isrigidly mounted to a stationary frame.
 10. The winch drum tensionisolation system of claim 1, further comprising a torque arm coupled tothe winch drum, and a winch frame, the winch drum and the lockingmechanism both coupled to the winch frame.
 11. The winch drum tensionisolation system of claim 10, further comprising a ram that drives thetorque arm.
 12. The winch drum tension isolation system of claim 10,further comprising an anchor point coupled to the winch frame.
 13. Thewinch drum tension isolation system of claim 12, further comprising ananchor pin extending through the anchor point and the torque arm torestrain movement of the torque arm.
 14. The winch drum tensionisolation system of claim 1, wherein the locking mechanism includes arestraining mechanism to restrain movement of the locking member, therestraining mechanism including a flange at an end of the lockingmember.
 15. A conveyor system comprises: a winch frame; a conveyorextending through the winch frame; a winch drum coupled to the winchframe that drives the conveyor, the winch drum including an outwardlyextending flange having a plurality of holes spaced along the flange; atorque arm coupled to both the winch frame and the winch drum; a motorand gearbox that drives rotation of the winch drum; a park brake thatprovides emergency braking force to the motor and gear box; and alocking mechanism positioned proximate the winch drum and including alocking member engageable with the flange, the locking member movablebetween a first position, in which the locking member is received in oneof the plurality of holes to prevent rotation of the winch drum, and asecond position, in which the locking member is spaced apart from theflange to permit rotation of the winch drum.
 16. The conveyor system ofclaim 15, wherein the winch drum includes a central portion having afirst diameter, and the flange has a second diameter greater than thefirst diameter.
 17. The conveyor system of claim 15, wherein the flangeincludes an outer radial circumference.
 18. The conveyor system of claim15, wherein the plurality of holes are spaced circumferentially aboutthe flange.
 19. The conveyor system of claim 15, wherein the pluralityof holes are spaced evenly apart along the flange.
 20. The conveyorsystem of claim 15, wherein the locking member is a spring-loaded pin.21. The conveyor system of claim 15, wherein the locking mechanismincludes a housing and the locking member is slidable through thehousing.
 22. A winch drum tension isolation system comprising: a winchdrum including an outwardly extending flange, the flange including aplurality of holes spaced along the flange; a locking mechanismpositioned proximate the winch drum and including a locking memberengageable with the flange, the locking member movable between a firstposition, in which the locking member is received in one of theplurality of holes to prevent rotation of the winch drum, and a secondposition, in which the locking member is spaced apart from the flange topermit rotation of the winch drum; a torque arm coupled to the winchdrum; and a winch frame, wherein the winch drum and the lockingmechanism are both coupled to the winch frame.
 23. A winch drum tensionisolation system comprising: a winch drum including an outwardlyextending flange, the flange including a plurality of holes spaced alongthe flange; a locking mechanism positioned proximate the winch drum andincluding a locking member engageable with the flange, the lockingmember movable between a first position, in which the locking member isreceived in one of the plurality of holes to prevent rotation of thewinch drum, and a second position, in which the locking member is spacedapart from the flange to permit rotation of the winch drum, wherein thelocking mechanism further includes a restraining mechanism to restrainmovement of the locking member, the restraining mechanism including aflange at an end of the locking member.